Locking device with embedded circuit board

ABSTRACT

Electrified access-control technology devices for a door, particularly electrified locks for a door, having embedded circuitry therein, and methods of making the same. One or more printed circuit boards (PCBs) having various electronic circuitry are secured inside a housing that encases an access-control device, particularly a lock, for a door. The one or more PCB(s) may be embedded on an internal surface of the housing such that the embedded PCB resides inside the housing along with the lock itself. The embedded PCB(s) avoid interference of both any working components of the lock inside the housing and any openings residing in the housing.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to embedded circuitry, and moreparticularly, to circuit boards embedded inside an access-controltechnology device of a door to provide electrification thereto.

2. Description of Related Art

There are currently various types of access-control technology devicesavailable for use with, on or inside a door. For instance, it is knownto use access-control technology in locking devices. In recent years,access-control technology in locking devices has increasingly shiftedfrom traditional keying systems and mechanical articulation to digitalmonitoring and electronic actuation. Various electronically actuatedlocks and exit devices for doors exist in the art. These electronicallyactuated locks are generally classified into two categories, namely,those having electronic circuitry housed inside a mortised recess of adoor, and those having electronic circuitry housed in an escutcheon-typelock assembly.

In mortised recess assemblies, electronic circuitry is housed in amortised recess of a door whereby this mortised recess is separate froma mortise housing the locking device of the door. In escutcheon-typeassemblies, the electronic circuitry is housed in a casing that resideson the exterior of the door, and as such, is also separate from the lockdevice itself.

In both of these types of assemblies, since the electronic circuitry isexternal to the lock itself, intricate wiring is required to provide thenecessary electrical connection between the external circuitry and thelock device. This entails routing wiring from the external electroniccircuitry, into the lock, and discretely throughout the lock in apattern that avoids the mechanical working components of the lock. Therouted wiring inside the lock is connected to switches and actuatorsresiding therein for providing an electronically actuated and monitoredlock.

Whether the electronic circuitry resides in a mortised recess or anescutcheon, it has been found that there are many disadvantages to theseconventional electronically actuated lock assemblies.

With the constrained real estate in a majority of currently availablelocks, it has become difficult and burdensome to provide the necessarywiring into and throughout the lock for the electrical connectionbetween the switches and actuators in the lock and the electroniccircuitry external to the lock. Concerns are also raised when too muchelectrical wiring resides external to the locking device. Insulated wireharnesses routed through a lockbody are subject to damage from contactwith mechanical components.

It is also undesirably burdensome, time consuming, expensive and expendsvaluable real estate within the lock by requiring the lock casing to befabricated with a number of holes and slots for accommodating theinserted wiring, as well as to be fabricated with brackets or harnessesinside the lock for securing and positioning the wiring accommodatedtherein. As such, these conventional mortised recess and escutcheon-typelock assemblies suffer from fabrication difficulties as well asperformance limitations in providing accurate wire routing to switches,actuators, and wire harnesses within existing mechanical lock mechanismshaving constrained real estate.

Additional drawbacks of housing electronics in an escutcheon is thatthese types of assemblies reside on and project outward from theexterior of the door, often precluding the addition of auxiliaryhardware on such door. Escutcheon-type assemblies are also less vandalresistant by virtue of its visibility and accessibility on the surfaceof the door. Further drawbacks of the mortised recessed housedelectronics include the increased difficulty for door manufacturers andinstallers to provide the precise sizing and shape of the mortisedrecess that fits the housing in which the electronics reside.

Accordingly, a need exists in the art for improved methods and apparatusfor access-control technology devices available for use with, on orinside a door. One of these needs is for improved methods and apparatusfor access-control technology in locking devices that allows digitalmonitoring and electronic actuation to be implemented in current lockingdevices that have constrained real estate. This constrained real estatemay be due to more compact designs, or even those existing mechanicallock mechanisms having increased and/or improved technological advancesresiding inside the lock that consume an increased and/or substantialportion of the valuable real estate therein.

SUMMARY OF THE INVENTION

Bearing in mind the problems and deficiencies of the prior art, it istherefore an object of the present invention to provide methods andapparatus for fabricating access-control technology as electrifiedaccess-control technology having embedded circuitry therein.

It is another object of the present invention to provide methods andapparatus for converting currently existing mechanically operatedaccess-control technology into digitally monitored and electricallycontrolled and actuated access-control technology.

Another object of the present invention is to provide methods andapparatus for converting an existing mechanical access-controltechnology device for a door into an electrified access-controltechnology device for a door that has capabilities for digitalmonitoring and electronic control and actuation.

It is yet another object of the present invention to provide methods andapparatus for converting an existing mechanical lock into an electrifiedlock having capabilities for digital monitoring and electronicactuation.

A further object of the invention is to provide methods and apparatusfor easily and efficiently electrifying existing access-controltechnology (e.g., an existing mechanical lock) having constrained realestate.

Still another object of the invention is to provide methods andapparatus for easily and efficiently providing existing access-controltechnology (e.g., an existing mechanical lock) with increasedperformance capabilities by securing a printed circuit board within themechanical lock housing.

It is another object of the present invention to provide a unifieddesign that allows for alternate circuit boards to be developed, whichaccomplishes different functions (i.e. modularity and future-proofing).

Another object of the present invention is to provide methods andapparatus for electrifying existing access-control technology (e.g., anexisting mechanical lock) easily, efficiently and cost effectively.

Still other objects and advantages of the invention will in part beobvious and will in part be apparent from the specification.

The above and other objects, which will be apparent to those skilled inthe art, are achieved in the present invention which is directed to anelectrified access-control device that includes a housing having atleast one side with an internal surface facing an inside of the housingand an access-control device residing in the inside of the housing. Achannel resides in the internal surface of the at least one side insidethe housing, and a printed circuit board (PCB) resides within thechannel inside the housing. The PCB has various electrical componentsattached thereto for electrifying the access-control device.

In one or more embodiments, the access-control device may be a lock thatis electrified by the PCB, whereby the electrified lock is provided withboth digital monitoring and electronic actuation capabilities. Suchlocks may include, but are not limited to, a mortise lock, a bored lock,a cylindrical lock, a tubular lock, an auxiliary lock, and a deadbolt.In alternative embodiments, the access-control device may be an exitdevice, an electronic door strike, a door closer, or a door operator. Inone or more embodiments the channel is embedded within the internalsurface of the housing side, whereby the PCB has a configurationmatching the embedded channel's configuration so that the PCB ismatingly embedded within the recessed channel. The exposed surface ofthe embedded PCB may be planar with a surface of the at least one side,whereby the embedded PCB covers over a distance of more than 50% of adiagonal distance across a surface area of the internal surface of thehousing side.

Also in one or more embodiments, a plurality of channels may reside onthe internal surface of the at least one side inside the housing, alongwith a plurality of PCBs corresponding to configurations of each of theplurality of channels. The plurality of PCBs may be embedded withinrespective ones of the plurality of channels inside the housing. Variouselectrical components may be attached to the plurality of embedded PCBsfor electrifying the access-control device. In one or more embodiments,the various electrical components attached to the embedded PCBs mayinclude, but are not limited to, one or more sensors, actuators, surfacemount connectors, signal output devices, accelerometers, temperaturesensors, heating components, and combinations thereof.

In other aspects, the invention is directed to an electrifiedaccess-control device for a door that includes a housing having a firstside and a second side, whereby each of the first and second sides havecorresponding internal surfaces facing an inside of the housing, with anaccess-control device being a lock residing inside the housing. At leastone recessed channel resides in the internal surface of either the firstor second side of the housing, while at least one PCB is embedded withinthe recessed channel in the internal surface of either the first orsecond side of the housing. A variety of electrical components areattached to the PCB to electrify the lock.

In the one or more embodiments of the invention, the variety ofelectrical components may provide the electrified lock with digitalmonitoring and/or electronic actuation capabilities, while theelectrified lock may include, but is not limited to, a mortise lock, abored lock, a cylindrical lock, a tubular lock, an auxiliary lock, or adeadbolt. The at least one embedded PCB may be a single PCB having asinusoidal shape that covers over a distance of more than 50% of adiagonal distance across a surface area of the internal surface of thehousing side in which the PCB is embedded. In one or more embodiments anexposed surface of the at least one recessed channel may have one ormore openings therein to access a backside of the at least one PCB. Theat least one recessed channel and the at least one embedded PCB may havematching configurations, whereby these matching configurations avoidinterference with working components of the lock and/or openings in thehousing. An exposed surface of the embedded PCB may be planar with anexposed surface of the internal surface of the housing side in which thePCB is embedded.

In further embodiments of the invention, the variety of electricalcomponents include one or more sensors residing on the PCB andpositioned at various locations across the PCB, the various locationscorresponding to locations where one or more magnets reside onmechanical working components of the lock, whereby the one or moresensors sense the one or more magnets to detect positions of themechanical working components of the lock. These sensors may include,but are not limited to, non-contact sensors, analogue transducers, hallsensors, electrical switches, reed switches, reed sensors, andcombinations thereof. One or more of these sensors may be raised awayfrom an exposed surface of the PCB to sense the one or more magnetsresiding adjacent an opposing side of the housing. The variety ofelectrical components may also include one or more sensors that do notrequire a magnet for triggering.

In still further embodiments, the variety of electrical components mayinclude an actuator residing inside the housing and in electricalcommunication with the PCB. This actuator may be, but is not limited to,a solenoid, motor, brush DC motor, stepper motor, piezo motor, and shapememory actuator. The variety of electrical components may also includeone or more surface mount connectors attached to the PCB. In one or moreembodiments the electrical components may include one or more electricalcomponents surface mounted to a surface of the PCB including, but notlimited to, an accelerometer, temperature sensors, heating components,and combinations thereof. The electrical components may also include oneor more signal output device connected to the PCB, whereby the signaloutput device converts various electrical output signals from the PCBinto one or more digital output signals. For instance, the signal outputdevice may be a controller board or a wire harness.

Also in one or more embodiments, the electrified access-control devicemay include a plurality of channels recessed within one or more of thefirst or second sides of the housing, along with a plurality of PCBscorresponding to configurations of the plurality of recessed channels,whereby each of the plurality of PCBs is embedded within respective onesof the plurality of recessed channels. The various electrical componentsattached to the plurality of embedded PCBs electrify the lock. Theseplurality of embedded PCBs may reside on the first side alone, thesecond side alone, or both the first and second sides of the housing,whereby the plurality of embedded PCBs are in electrical communicationwith one another to electrify the lock.

In still other aspects, one or more embodiments of the invention aredirected to methods of fabricating an electrified lock by providing ahousing having a first side having an internal surface facing an insideof the housing and providing a mechanical lock inside the housing. Asecond side of the housing is fabricated to have at least one recessedchannel residing in a surface thereof, and at least one PCB having avariety of electrical components attached thereto is embedded within therecessed channel in the surface of the second side. The mechanical lockis converted into an electrified lock by attaching the second side tothe housing so that the surface of the second side having the embeddedPCB faces the inside of the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention believed to be novel and the elementscharacteristic of the invention are set forth with particularity in theappended claims. The figures are for illustration purposes only and arenot drawn to scale. The invention itself, however, both as toorganization and method of operation, may best be understood byreference to the detailed description which follows taken in conjunctionwith the accompanying drawings in which:

FIG. 1A is a top elevational view of a locking device housing sidehaving a recessed opening therein for receiving a printed circuit board(PCB) in accordance with one or more embodiments of the invention.

FIG. 1B is a top elevational view of a PCB of the invention having aconfiguration that is selected to avoid interference with any mechanicalworking components within a mechanical locking device. A variety ofelectrical components are surface mounted to the PCB so that thebackside of the PCB remains substantially planar.

FIG. 1C is a top elevational view showing the PCB of FIG. 1B positionedover the recessed opening in the housing side of FIG. 1A.

FIG. 1D is a top plane view showing the PCB of FIG. 1C embedded into therecessed opening in the housing side.

FIG. 1E is a side view showing one or more PCBs of the inventionembedded within one or more lateral sidewalls of a locking devicehousing, with the embedded PCBs being in electrical communication withone another. As shown, each PCB has a thickness equivalent to a depth ofits corresponding recessed opening so that after embedding the PCB intothe recess, the surface of the PCB is planar with the remaining internalsurface of the side in which the PCB resides to avoid interference withthe mechanical working components of the lock.

FIG. 1F is another side view showing a single PCB module in accordancewith one or more embodiments of the invention embedded into lateral sideof a locking device housing, whereby the PCB may have electroniccomponents adjacent the surface of the PCB and/or electronic componentsthat extend into the locking device to detect motion and multiplepositions of the working components of such lock.

FIGS. 2A-B are a side elevational view and a top plane view,respectively, showing that multiple PCBs having surface mount technologymay be embedded within one or more sidewalls inside a locking devicehousing in accordance with one or more embodiments of the invention.

FIGS. 3A-C show side elevational views of one or more embodiments of theinvention whereby one or more PCBs of the invention are embeddeddirectly inside a mortise lock housing to convert a mechanical mortiselock into an electrified mortise lock having capabilities for digitalmonitoring and electronic actuation.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

In describing the embodiments of the present invention, reference willbe made herein to FIGS. 1A-3C of the drawings in which like numeralsrefer to like features of the invention.

In one or more embodiments, the invention integrates electroniccircuitry within existing and future locking devices. The lockingdevices suitable for use include those housed either entirely orpartially within a housing, wherein one or more electronic circuitboards may be embedded in accordance with the various embodiments of theinvention. These locking devices include, but are not limited to, amortise lock, a bored lock, a cylindrical lock, an electric strike, atubular lock, an auxiliary lock, and a deadbolt and the like.

Referring to FIGS. 1A-F, at least one interior surface 11, 13 of alocking device housing 10 is provided with a channel 12 that correspondsto the shape, size and thickness of a corresponding printed circuitboard (PCB) 20. In one or more embodiments, this channel 12 is arecessed channel residing within a thickness of a housing side. Theinterior surfaces of the locking device housing 10 may include anyinterior surface within the housing 10 including, but not limited to, afirst interior surface 11 of a first side 18 of the housing, a secondinterior surface 13 of a second side 19 of the housing, and so on. Atleast two or more of these interior surfaces of their respective sidesmay oppose one another, e.g., interior surface 11 of side 18 opposesinterior surface 13 of side 19, with the mechanical working componentsof the lock residing there-between.

Both the recessed channel 12 and the PCB 20 have corresponding shapesand sizes configured so that they avoid interference with mechanicalworking components of the locking device. Mechanical working componentsinclude latch bolts, dead bolts, cylinder locking mechanisms, blockingmechanisms, hubs, cams, levers, and the like. These shapes and sizes ofthe recessed channel 12 and PCB 20 also avoid interference with anyopenings in the housing 10 including, but not limited to, lock cylinderopenings, screw or bolt openings, spindle openings, threaded openings,blocking openings, and the like.

The recessed channel 12 may be formed in one or more interior surfaces11, 13 of the housing 10 sides 18, 19 using known techniques including,for example, stamping, routing, machining, cast molding, and the like.This recessed channel 12 may be formed in the sides 18, 19 to a depth“B” that is less than the total thickness “A” of its respective side 18,19. The PCB 20 is formed to a thickness that is substantially equivalentto the depth “B” of the recessed channel, such that, upon positioningand embedding the PCB 20 into the recessed channel 12, a surface of thePCB 20 is substantially planar with the interior surface 11, 13 of theside 18, 19 in which the PCB resides, as is shown in FIGS. 1E-F.

In one or more embodiments, the first side 18 alone may be provided withan embedded PCB 20, the second side 19 alone may be provided with anembedded PCB 20, or alternatively, both the first and second sides 18,19 of the locking device housing 10 each may be provided with one ormore embedded PCBs 20 in accordance with the invention. That is,referring to FIGS. 1E and 2A-B, a plurality of recessed channels 12 a,12 b, 12 c may be formed in one or more sides of the housing, wherebycorrespondingly shaped and sized PCBs 20 a, 20 b, 20 c are provided andembedded therein. These plurality of PCB's 20 a, 20 b, 20 c may beelectrically wired to one another either within the housing 10, or byproviding openings 30 a, 30 b, 30C at a bottom of the correspondingrecessed channels 12 a, 12 b, 12 c, and through the use of conductivewiring 32, making the electrical wiring connections between the PCB's 20a, 20 b, 20 c through these openings 30 a, 30 b, 30C.

As an alternative to the multiple embedded PCBs 20 a, 20 b, 20 c, oreven in combination therewith, in one or more embodiments the PCB may bea single continuous circuit board embedded within an interior surface ofone or more of the sides of the locking device housing 10, as shown inFIGS. 1A-F. Like that of the multiple embedded PCBs 20 a, 20 b, 20 c,the single continuous PCB is configured with a shape and thickness thatdoes not interfere with any working or moving components inside themechanical lock. For instance, referring to the drawings, the PCB mayhave a shape that carries electrical wiring on the circuit board betweenthe top 16 and bottom 17 of the lock and simultaneously between the leftand right lateral sides 18, 19 of the lock. In one or more embodimentsthis shape may be a sinusoidal shape that covers over a distance of morethan 50%, and even more than 60%, of the diagonal distance across thesurface area of the side in which such sinusoidal shaped embedded PCBresides.

Referring again to the multiple embedded PCBs 20 a, 20 b, 20 c, thesePCBs also provide electrical wiring connections between the multiplecircuit boards from top 16 to bottom 17 and left to right lateral sides18, 19 of the lock. As such, the multiple PCBs may also cover over adistance of more than 50%, and even more than 60%, of the diagonaldistance across the surface area of the housing side in which suchmultiple PCBs reside. It also should be appreciated that when two ormore interior surfaces of the locking device housing 10 simultaneouslyeach contain one or more embedded PCB(s), the circuit boards embeddedwithin these multiple interior surfaces may be electrically connected toone another via wiring extending from one side of the housing 10 to theother side of the housing 10. This wiring may reside inside the lockingdevice housing 10 (e.g., it may be contained within another circuitboard), or it may reside outside the locking device housing andelectrically connect the PCBs to one another through the openings 30residing at the bottom of the recessed channels 12.

Referring to FIGS. 1E-F, the backside of each of the present PCB(s) 20is substantially planar. In this manner, when the PCB 20 is positionedin the recessed channel 12, which also has an exposed substantiallyplanar surface, a flat mating connection is made between the surfaces ofthe recessed channel and the backside of the PCB. Optionally, a barrierlayer may be provided between the exposed surface of the recessedchannel 12 and the backside of the PCB including, but not limited to, aninsulator, a paste, an adhesive, and the like. Again, the exposedsurface of the recessed channel 12 may optionally have one or moreopenings 30 traversing there-through. These openings 30 also allowelectrical circuitry outside the lock to be connected via wiring to anelectrical connector that may reside on the backside of the PCB inlocations corresponding to the openings 30. A ground plate may alsoreside on the backside of the PCB along with the one or more electricalconnector(s) or as a stand alone feature.

As shown in the drawings, the PCBs of the various embodiments of theinvention each have a thickness substantially equivalent to thethickness or depth of the corresponding recessed channel into which suchPCB is to be embedded. In this manner, once embedded therein, theexposed surface(s) of the PCB(s) and the exposed interior surface(s) ofthe housing side in which the recessed portion(s) reside aresubstantially planar with one another, as is shown in FIGS. 1E-F. Byproviding a planar surface with the interior housing side, the embeddedPCB(s) minimize, or all together avoid, modifications to and/orrearrangements of existing mechanical working components of the lockingdevice, avoid moving parts within the locking device, and optimize thepositioning of sensors, magnets and/or actuators within the lockingdevice as discussed further below.

Optionally, in locations that do not interfere with lock openings and/orworking components multi-surface mount technology may be employed bymounting one or more additional circuit boards on top of the embeddedPCB to provide the electrified lock with increased processing power.These additional surface mounted circuit boards extend upward from asurface of the embedded PCB into the locking device (may be parallel orperpendicular to the embedded PCB).

Either before or after the PCB is embedded inside the housing side,various electrical components may be surface mounted to the PCB instrategic locations across the board. In one or more embodiments, theworking components of the mechanical lock may be provided with magnets55 at various locations. These magnets 55 may reside on a surface of theworking components, be inset into the surface of the working component,or even be imbedded inside the working component itself. The pluralityof magnets 55 residing on the lock's working components provides theability to monitor the working components at multiple locations todetect multiple positions, including opened and closed positions, ofsuch working components, as opposed to conventional methods andapproaches that only allow the monitoring and detection of opened andclosed positions due to wire routing, size, and space constraints.

The PCB(s) of the invention may be provided with one or more sensors 50at various locations across the PCB. A bypass capacitor 52 may beconnected to each sensor 50 to eliminate system noise and avoid sensoroscillations. The sensors attached to the PCB include, but are notlimited to, non-contact sensors, analogue transducers, hall sensors,electrical switches, reed switches, and the like. These sensors 50 areattached at positions corresponding to the magnets on the mechanicalworking components of the lock for sensing the positions of thesevarious mechanical lock components. As the working component with itsmagnet moves or rotates, the magnet is brought into or out of closeproximity with a sensor mounted on the PCB, thereby enabling monitoringof the door and/or lock movement to detect opening and closing of thedoor, tampering with and/or vandalism to the lock or door, actuation oflevers or bolts, and the like.

In some embodiments, one or more sensor(s) 51 may be raised away fromthe surface of the PCB, such that, the raised sensor extends toward theother side of the housing for sensing magnets residing at or near thisother side of the housing. As an alternative, an embedded PCB may residein this other side of the housing and have one or more surface mountedsensors for detecting a magnet near this side, whereby the embedded PCBson opposing sides may be connected to one another via electrical wiring.

Other electrical components that may be mounted to the PCBs of theinvention include sensors 54 that do not require a magnet fortriggering. These sensors may include, but are not limited to,mechanical micro-switches, a Magnasphere sensor, push buttons, opticalsensors, and the like. An actuator 60 may also be attached to thehousing side in which the embedded PCB resides to drive the lockcomponents to lock and/or unlock the lock. The actuator 60 is attachedto the housing side in a location that is in close proximity to the PCBso that the actuator 60 is electrically powered by the PCB via wiringand a connector. As an alternative, the actuator may be directlyassembled to the PCB. Actuators 60 suitable for use in the variousembodiments of the invention include, but are not limited to, solenoids,motors, brush DC motors, stepper motors, piezo motors, shape memoryactuators, and the like. If increased electrical current is required,such as with the use of a solenoid actuator, traces may be routedthrough a middle PCB layer or the board may be conformally coated withan insulation layer to protect external circuits and components.

The PCBs may also be provided with one or more surface mount connectors70 having inputs for electrical connection to the actuator 60. Otherelectrical components surface mounted onto the surface of the PCB thatresides inside the lock include, but are not limited to, anaccelerometer, temperature sensors, heating components, and the like. Anaccelerometer enables the measuring or impact on the door to detect ifthe door is being closed, if the door is being impacted or hit (e.g.,someone vandalizing the door), and the like. Temperature sensors enablethe measuring of the temperature inside the lock. A heating componentprovides heat inside the lock to control the internal lock temperatureto prevent freezing and maintaining the workability of the internalmechanical lock components.

A signal output device 80 may be connected to the PCB. This signaloutput device 80 may be a controller board as shown in FIGS. 1B and 1D,or it may be a wire harness as shown in FIG. 2B. The signal outputdevice 80 is an electronic module on the PCB that intakes the electricalsignal outputs from the various electronic components residing on or inelectrical communication with the PCB 20 and converts these inputs intoa readable, digital output signal. For instance, a WIFI orcommunications module (e.g., Ethernet, bluetooth, and the like) may beassembled into the device 80 mounted on the PCB to link the PCB to acentralized lock control system. As such, this WIFI or communicationsmodule is embedded inside the lock.

At various locations across the present PCBs, selected ones or each ofthe PCBs may be provided with a number of openings 90 in the PCB. Theseopenings 90 may reside in locations on the PCB corresponding tolocations of working components of the lock, in locations correspondingto positions where external devices may be inserted into the lock, inlocations corresponding to where screw 92 may be inserted to secure thehousing side to the rest of the lock housing, and the like.

In accordance with the various embodiments of the invention, anaccess-control device 100 shown in FIG. 3C, for example, as aconventional mechanical locking device is converted into an electrifiedlock having electronic monitoring capabilities by providing one or moreof the embedded PCBs of the invention therein. The present PCBconfigurations allow complex circuits to be integrated into an internalassembly, and in one or more embodiments into a single internalassembly, for easy and efficient conversion of an access-control device100, for example, of ordinary existing mechanical lock with its internalworking lock components into one that is an electrified lock. Theinvention has many advantages over the conventional methods andapproaches of positioning switches and actuators and then routing andsecuring individual wires and/or wiring harnesses at numerous locationsinside and outside the lock for connecting sensors at various locationsacross the lock and to an external harness or connector in order toelectrify the lock. Some of these advantages include that the presentinvention provides an easy and efficient approach for electrification ofan existing mechanical locking mechanism without significant mechanicalredesign, challenging wire routing, and the limitations of switch oractuator positioning. The invention decreases costs, easesmanufacturing, increases the performance capabilities that may beprovided inside the existing mechanical lock, and provides a modularassembly that can be embedded inside the lock housing quickly andeasily. Outsourcing of modular sub-assemblies also becomes possible toreduce cost.

Whether one or more PCBs are embedded inside a lock device housing, theinvention enables the utilization of the embedded PCB(s) for allelectronic functions within a locking mechanism to increase performancecapabilities including, but not limited to, precise sensing, actuation,circuit routing, efficient electrical connectivity, signal conditioning(e.g., AC rectification), communications (e.g., WiFi, bluetooth, etc.),logic control, micro-processing which can condition the signals forinput or output, signaling (e.g., LED, status indicators, etc.), andstandardized connectorization to external circuits. The embedded PCBs ofthe invention may also be equipped with wireless or cellular circuitsthat may connect to an external antenna.

Again, the shape, size and length of each PCB of the invention, orcombinations of PCBs, allow electrical wiring to be provided from oneend of the lock to another end of the lock (e.g., from the bottom to thetop of the lock). In one or more embodiments, the PCB(s) is providedover a diagonal distance across the lock from top to bottom, and viceversa, whereby multiple sensors are strategically positioned on the PCBto sense the magnets residing in or on the mechanical working componentsto detect the movement thereof. As such, the present PCBs provide all ofthe wiring within the lock housing and simultaneously provide thepositioning for the various sensors within the lock that are used todetect motion of the mechanical lock components. This allows thecircuitry to determine when the lock is open, when the dead bolt hasbeen operated, when the dead bolt is in motion, and the like.

By embedding PCBs within an internal surface of a locking device housing10, the various embodiments of the invention are suitable for use withthose locking devices having constrained real estate. The inventionconverts a locking device having constrained real estate from a strictlymechanical locking device into an electrified lock having capabilitiesfor digital monitoring and electronic actuation directly inside thelocking device itself. These locking devices with constrained realestate may include existing locking devices having more compact designs,existing mechanical locking devices having increased and/or improvedtechnological advances residing inside the locking device that consumean increased or substantial portion of the valuable real estate withinthe lock, and even future lock designs configured with constrained realestate.

While not meant to limit the invention, one or more embodiments of theinvention are suitable for use with locking device housings 10 thatencase the mechanical lock device components. For instance, one suchsuitable lock encasing is a mortise lock housing 110 as shown in FIGS.3A-C. A mortise lock housing 110 includes a lateral side 119 being acover plate and a casing portion. The casing portion of the mortise lockhousing includes top 160 and bottom 170 walls, a back wall 140 and alateral sidewall 118 that opposes the cover plate lateral side 119 whenthe housing is assembled. A front plate 128 resides opposite the backwall 140 and between sides 118, 119. Again, in one or more embodiments,an interior surface 111 of the first lateral sidewall 118 alone, aninterior surface 113 of the cover plate 119 alone, or interior surfaces111, 113 of both the sidewall 118 and the cover plate 119 of the mortisehousing 110 may be provided with one or more embedded PCBs 120 inaccordance with the invention.

Referring to FIG. 3C, a single embedded PCB 20 assembly of the inventionis shown whereby the PCB is embedded in the lateral sidewall 118 of thehousing casing behind the internal working components of the mortiselock. The exposed surface of the embedded PCB 20 is planar with aninternal surface 111 of the lateral side 118 in which the embedded PCBresides, while the backside of the PCB 20 is in direct contact and flushwith the inner surface of the recess/routed out depression in the sidein which the PCB resides. The surface of PCB is provided with surfacemount technology which allows the wiring and the components to belocated entirely on the upper surface of the PCB that is exposed insidethe lock. Again, the backside of the PCB optionally may include a groundplate and/or a connector that has a corresponding opening in the side118, 119 allowing an electrical connector to be attached to the PCB fromoutside of the lock.

The embedded PCB 20 is configured with a shape, size and thickness thatdoes not interfere with the positioning of the lock's working componentsresiding inside the housing 110 and allows the PCB to pass around thevarious openings in the mortise lock. These working components residinginside the mortise lock include components connected to handle actuatorsto throw the dead bolt and the various pivots supported by the coverplate for components that move within the mortise lock. For instance,the working components may include, but are not limited to, a controlhub 132, spindle hubs 134, 136, spindle openings 138, a latch bolt 142having a latch bolt tail 140, a shaft 150 turned by a rotatable element148, a latch retract lever 162, a lock cylinder opening 60 that mayrotate the control hub 132 and the like.

In the various embodiments of the invention, one or more, or even all,of these working components of the mortise lock may be provided with oneor more magnets 55 on or inserted into a surface thereof. With the PCB20 configured to avoid the openings in the mortise lock and theseworking components, while still residing in close proximity thereto, thesensors 50 are strategically positioned on a surface of the PCB so thatthe sensors 50 are in close proximity to the various magnets 55 fordetecting and monitoring motion of these working components of the lock.

Some of the sensors 50 may reside on the PCB while other sensors 51 maybe connected with leads to allow the sensor 51 to stand up and away fromthe surface of the PCB. In this manner, the sensor 51 is projected intothe lock mechanism toward the opposing sidewall to detect magnets 55residing on locking components that reside adjacent or near thisopposing sidewall. For instance, referring to FIG. 3C, the two spindlehubs 134, 136 each have a corresponding oval comprising a magnet 55. Thespindle hub 136 closest to the PCB has a corresponding sensor 50 mounteddirectly on the surface of the PCB, while the spindle hub 134 locatedfarthest from the PCB is sensed by a sensor 51 that is raised off thesurface of the PCB and resides within the mechanical lock.

Once the interior surface of the lateral sidewall 118, the cover plate119, or both the lateral sidewall 118 and the cover plate 119, have beenprovided with one or more embedded PCB(s) in accordance with theinvention, the now electrified mortise lock is secured within a mortiserecess 260 residing between front 214 and back 212 surfaces of a door200. Accordingly, the various embodiments of the invention provide forthe easy and efficient conversion of a conventional mortise lock into anelectrified mortise lock having electronic capabilities, particularly,digital monitoring and electronic actuation inside the locking deviceitself. In one or more embodiments, the electrified mortise lock of theinvention includes one or more PCBs configured to carry wiring from oneportion of the mortise lock to another portion of the lock for theelectrical connection of a variety of components residing on the PCB toprovide the lock with hall effect and/or reed sensing, solenoidactuation for electrified locking and/or unlocking the mortise lock,minimal mechanical modifications, embedded magnets, on-board processingand/or communications linked to a centralized lock control system, andthe like.

It should be appreciated that the housing side containing the embeddedPCB may be configured as a universal lock housing side (e.g., auniversal lock housing cover plate) for installation in existing lockdevices having no electronic components. In this manner, a conventionalnon-electric lock having reduced cost, high volume, lock components maybe converted into an electrified lock that has electrical monitoring andactuation capabilities.

It should be appreciated that in one or more embodiments of theinvention the PCB(s) may be secured directly inside other types ofhoused locks including, for example, a cylindrical lock. In this aspect,an internal surface within the cylindrical lock (e.g., the cylindricaloutside of the lock) may be provided with a recessed/routed outdepression for accommodating an embedded PCB. Alternatively, an internalsurface of the cylindrical lock may be provided with a mount forsecuring the PCB inside the lock. In either aspect, both the channel andthe PCB are configured to avoid any openings and/or working componentswithin the lock. The PCB is secured inside the channel so that theconventional cylindrical lock is converted from a non-electrified lockto an electrified cylindrical lock. For instance, the electrifiedcylindrical lock may include slotted mounts, reed sensing, an on-boardbridge rectified solenoid circuit, a motor circuit, an integrated earthground, a common wire harness connection and the like.

While not deviating from the novel concepts of the invention, thepresent embedded PCBs may be used in a variety of electronicallyactuated access-control devices 100 including, but not limited to, exitdevices, electronic door strikes, door closers, door operators,cylindrical locks, tubular locks, auxiliary locks, deadbolts, and thelike. For instance, one or more PCB may be embedded within the rail ofan exit device, embedded within a plate of the door strike or closer,and the like. Additionally, the present embedded PCBs may be used in avariety of electronically actuated access-control devices 100 thatemploy the use of various access user recognition systems including, butnot limited to, a key, a password, a card (e.g., the lock would includea slot for insertion of a card directly into a reader within the lock),magnetic components, a keypad, a fingerprint recognition device, an RFcard reader, a remote controller recognition system, and the like.

While still not deviating from the novel concepts of the invention ofhaving one or more PCBs residing inside a locking device itself, ratherthan embedding the board inside a side of the locking device housing,mounts or harnesses may be secured to an internal surface of the lockingdevice housing. These mounts or harnesses may reside in locations thatwill not interfere either with the various lock openings or with theworking components of the lock. The present PCBs may then be embeddedwithin the mount(s) or harness(es) residing on an interior surface ofthe housing so that the PCBs reside inside the locking device housingitself. Optionally, one or more of the working components inside thelock may be mechanically machined to remove a portion of the workingcomponent thickness so as to prevent and/or avoid contact with the PCBmounted onto the internal surface of such housing side.

While the present invention has been particularly described, inconjunction with a specific preferred embodiment, it is evident thatmany alternatives, modifications and variations will be apparent tothose skilled in the art in light of the foregoing description. It istherefore contemplated that the appended claims will embrace any suchalternatives, modifications and variations as falling within the truescope and spirit of the present invention.

1. An electrified access-control device comprising: a housing includingat least one side having an internal surface facing an inside of saidhousing; an access-control device residing in the inside of saidhousing; a channel residing on said internal surface of said at leastone side inside said housing; and a printed circuit board (PCB) residingwithin said channel inside said housing, said PCB having variouselectrical components attached thereto for electrifying saidaccess-control device, said variety of electrical components include oneor more surface mount connectors attached to said PCB.
 2. Theelectrified access-control device of claim 1 wherein said access-controldevice comprises a lock that is electrified by the PCB, the electrifiedlock being provided with both digital monitoring and electronicactuation capabilities.
 3. The electrified access-control device ofclaim 2 wherein said electrified lock is selected from the groupconsisting of a mortise lock, a bored lock, an electric strike, acylindrical lock, a tubular lock, an auxiliary lock, and a deadbolt. 4.The electrified access-control device of claim 1 wherein saidaccess-control device is selected from the group consisting of an exitdevice, an electronic door strike, a door operator and a door closer. 5.The electrified access-control device of claim 1 wherein said channel isrecessed within said internal surface of said at least one side insidesaid housing, said PCB having a configuration matching the recessedchannel's configuration so that said PCB is matingly embedded withinsaid recessed channel.
 6. The electrified access-control device of claim5 wherein an exposed surface of said embedded PCB is planar with asurface of said at least one side.
 7. The electrified access-controldevice of claim 6 wherein said embedded PCB covers over a distance ofmore than 50% of a diagonal distance across a surface area of saidinternal surface of said at least one side of said housing.
 8. Theelectrified access-control device of claim 1 further including: aplurality of channels residing on said internal surface of said at leastone side inside said housing; a plurality of PCBs corresponding toconfigurations of each of said plurality of channels, whereby saidplurality of PCBs are embedded within respective ones of said pluralityof channels inside said housing; and said various electrical componentsattached to said plurality of embedded PCBs for electrifying saidaccess-control device.
 9. The electrified access-control device of claim1 wherein said various electrical components are selected from the groupconsisting of one or more sensors, actuators, surface mount connectors,signal output devices, accelerometers, temperature sensors, heatingcomponents, and combinations thereof.
 10. An electrified access-controldevice for a door comprising: a housing having a first side and a secondside, each of said first and second sides having corresponding internalsurfaces facing an inside of said housing; an access-control devicebeing a lock residing within the inside of said housing; at least onerecessed channel residing in said internal surface of either said firstor second side of said housing; at least one printed circuit board (PCB)embedded within said recessed channel in said internal surface of eithersaid first or second side of said housing; one or more openings in anexposed surface of said at least one recessed channel to access abackside of said at least one PCB; and a variety of electricalcomponents attached to said PCB to electrify said lock.
 11. Theelectrified access-control device of claim 10 wherein said variety ofelectrical components provide said electrified lock with digitalmonitoring and electronic actuation capabilities.
 12. The electrifiedaccess-control device of claim 10 wherein said electrified lock isselected from the group consisting of a mortise lock, a bored lock, acylindrical lock, a tubular lock, an auxiliary lock, and a deadbolt. 13.The electrified access-control device of claim 10 wherein said at leastone embedded PCB comprises a single PCB having a sinusoidal shape thatcovers over a distance of more than 50% of a diagonal distance across asurface area of said internal surface of said housing side in which saidPCB is embedded.
 14. The electrified access-control device of claim 10wherein said at least one recessed channel and said at least oneembedded PCB have matching configurations.
 15. The electrifiedaccess-control device of claim 14 wherein said matching configurationsof said at least one recessed channel and said at least one embedded PCBavoid interference with working components of said lock and openings insaid housing.
 16. The electrified access-control device of claim 10wherein an exposed surface of said embedded PCB is planar with anexposed surface of said internal surface of said housing side in whichsaid PCB is embedded.
 17. The electrified access-control device of claim10 wherein said variety of electrical components include one or moresensors residing on said PCB and positioned at various locations acrosssaid PCB, said various locations corresponding to locations where one ormore magnets reside on mechanical working components of said lock,whereby said one or more sensors sense said one or more magnets todetect positions of said mechanical working components of said lock. 18.The electrified access-control device of claim 17 wherein said one ormore sensors are selected from the group consisting of non-contactsensors, analogue transducers, hall sensors, electrical switches, reedswitches, reed sensors, and combinations thereof.
 19. The electrifiedaccess-control device of claim 17 wherein at least one of said one ormore sensors is raised away from an exposed surface of said PCB to sensesaid one or more magnets residing adjacent an opposing side of saidhousing.
 20. The electrified access-control device of claim 10 whereinsaid variety of electrical components include one or more sensorsresiding on said PCB that do not require a magnet for triggering. 21.The electrified access-control device of claim 10 wherein said varietyof electrical components include an actuator residing inside saidhousing and in electrical communication with said PCB.
 22. Theelectrified access-control device of claim 21 wherein said actuator isselected from the group consisting of a solenoid, motor, brush DC motor,stepper motor, piezo motor, and shape memory actuator.
 23. Anelectrified access-control device for a door comprising: a housinghaving a first side and a second side, each of said first and secondsides having corresponding internal surfaces facing an inside of saidhousing; an access-control device residing within the inside of saidhousing; at least one recessed channel residing in said internal surfaceof either said first or second side of said housing; at least oneprinted circuit board (PCB) embedded within said recessed channel insaid internal surface of either said first or second side of saidhousing; and a variety of electrical components attached to said PCB toelectrify said access-control device, wherein said variety of electricalcomponents include one or more surface mount connectors attached to saidPCB.
 24. The electrified access-control device of claim 10 wherein saidvariety of electrical components include one or more electricalcomponents surface mounted to a surface of said PCB selected from thegroup consisting of one or more sensors, actuators, surface mountconnectors, signal output devices, accelerometer, temperature sensors,heating components, and combinations thereof.
 25. The electrifiedaccess-control device of claim 10 wherein said variety of electricalcomponents include one or more signal output device connected to saidPCB, said one or more signal output device converts various electricaloutputs signals from said PCB into one or more digital output signals.26. An electrified access-control device for a door comprising: ahousing having a first side and a second side, each of said first andsecond sides having corresponding internal surfaces facing an inside ofsaid housing; an access-control device residing within the inside ofsaid housing; at least one recessed channel residing in said internalsurface of either said first or second side of said housing; at leastone printed circuit board (PCB) embedded within said recessed channel insaid internal surface of either said first or second side of saidhousing; and a variety of electrical components attached to said PCB toelectrify said access-control device, wherein said variety of electricalcomponents include one or more signal output device selected from thegroup consisting of a controller board and a wire harness connected tosaid PCB, said one or more signal output device converts variouselectrical outputs signals from said PCB into one or more digital outputsignals.
 27. An electrified access-control device for a door comprising:a housing having a first side and a second side, each of said first andsecond sides having corresponding internal surfaces facing an inside ofsaid housing; an access-control device residing within the inside ofsaid housing; a plurality of channels recessed within one or more ofsaid first or second sides of said housing; a plurality of PCBscorresponding to configurations of said plurality of recessed channels,each of said plurality of PCBs being embedded within respective ones ofsaid plurality of recessed channels; and a variety of electricalcomponents attached to said plurality of embedded PCBs to electrify saidaccess-control device, wherein said plurality of embedded PCBs reside onsaid first side alone, said second side alone, or both said first andsecond sides of said housing, whereby said plurality of embedded PCBsare in electrical communication with one another to electrify saidaccess-control device.
 28. An electrified access-control devicecomprising: a housing including at least one side having an internalsurface facing an inside of said housing; an access-control deviceresiding in the inside of said housing; a channel residing on saidinternal surface of said at least one side inside said housing; aprinted circuit board (PCB) residing within said channel inside saidhousing, said PCB having various electrical components attached theretofor electrifying said access-control device; and one or more openings inan exposed surface of said housing to access a backside of said PCB. 29.An electrified access-control device for a door comprising: a housinghaving a first side and a second side, each of said first and secondsides having corresponding internal surfaces facing an inside of saidhousing; an access-control device residing within the inside of saidhousing; at least one channel residing in said internal surface ofeither said first or second side of said housing; at least one printedcircuit board (PCB) residing within said channel; and a variety ofelectrical components attached to said PCB to electrify saidaccess-control device, said variety of electrical components include oneor more signal output device selected from the group consisting of acontroller board and a wire harness connected to said PCB, said one ormore signal output device converts various electrical outputs signalsfrom said PCB into one or more digital output signals.
 30. Anelectrified access-control device for a door comprising: a housinghaving a first side and a second side, each of said first and secondsides having corresponding internal surfaces facing an inside of saidhousing; an access-control device residing within the inside of saidhousing; a plurality of channels within one or more of said first orsecond sides of said housing; a plurality of PCBs corresponding toconfigurations of said plurality of channels, each of said plurality ofPCBs residing within respective ones of said plurality of channels; anda variety of electrical components attached to said plurality of PCBs toelectrify said access-control device, wherein said plurality of PCBsreside on said first side alone, said second side alone, or both saidfirst and second sides of said housing, said plurality of embedded PCBsare in electrical communication with one another to electrify saidaccess-control device.